Evaluation Report 278

Transcription

1 Printed: May, 1982 Tested at: Lethbridge ISSN Evaluation Report 278 Hesston Model 4600 Beeline Baler A Co-operative Program Between ALBERTA FARM MACHINERY RESEARCH CENTRE PAMI PRAIRIE AGRICULTURAL MACHINERY INSTITUTE

2 HESSTON MODEL 4600 BEELINE BALER MANUFACTURER: Hesston Corporation Hesston Kansas U.S.A. RETAIL PRICE: $11, (May, 1982, f.o.b. Lethbridge, complete with quarter turn bale chute). DISTRIBUTOR: Hesston Industries Limited No. 2, Avenue N.E. Calgary, Alberta T2E 7C7 FIGURE 1. Hesston Model 4600 Beeline Baler: (A) Power Take-off, (B) Slip Clutch, (C) Flywheel, (D) Twine Storage, (E) Knotters, (F) Metering Wheel, (G) Metering Arm, (H) Bale Density Adjustment, (I) Quarter-Turn Bale Chute, (J) Bale Chamber, K) Feed Chamber, (L) Feed Auger, (M) Pickup, (N) Stuffer Fingers, (O) Packer Fingers. SUMMARY AND CONCLUSIONS Overall functional performance of the Hesston 4600 Baler was very good. Average feedrates varied from 2 to 11 t/h (2.2 to 12.1 ton/h). Field speeds were usually limited to 10 km/h (6.2 mph) due to bouncing on rough ground and reduced pickup performance at higher speeds. Maximum instantaneous feedrates in excess of 22 t/h (24.2 ton/h) were measured in heavy uniform alfalfa windrows. Feeding was aggressive in all crops. The Hesston 4600 was capable of producing firm, well formed bales. Length of the 356 x 457 mm (14 x 18 in) bales could be adjusted from 305 to 1320 mm (12 to 52 in). Bale length variation, at the 1000 mm (39 in) setting, was about 100 mm (3.9 in). For a certain length setting, longer bales were usually produced at higher feedrates. Average hay bales weighed from 21 to 41 kg (45 to 90 lb), while average straw bales weighed from 21 to 24 kg (45 to 53 lb). Bale density varied from 254 kg/m³ (15.8 lb/ft³) in heavy alfalfa-bromegrass to 127 kg/m³ (7.9 lb/ft³) in light barley straw. The Hesston 4600 was easy to operate and adjust. Knotter performance was good with both sisal and synthetic twines as long as the knotters were properly adjusted. Average power requirements were usually less than 23 kw (31 hp) but a 45 kw (60 hp) tractor was needed to overcome power take-off fl uctuations and to provide sufficient power on hilly and soft fi elds. Total leaf and stem loss was usually less than 3%, similar to that of other conventional square balers. The Hesston 4600 was safe to operate if the manufacturer s safety recommendations were closely followed and normal safety precautions were observed. Only minor mechanical problems occurred during the test. The slip clutch required adjustment beyond the manufacturer s recommended slip torque for effi cient baling and the plunger safety stop required readjustment several times. Page 2 RECOMMENDATIONS It is recommended that the manufacturer consider: 1. Re-evaluating the power take-off shaft slip clutch slip torque setting given in the operator s manual. Senior Engineer: E. H. Wiens Project Technologist: P. A. Bergen THE MANUFACTURER STATES THAT With regard to recommendation number: 1. This recommendation is under consideration at the present time. NOTE: This report has been prepared using SI units of measurement. A conversion table is given in APPENDIX III. GENERAL DESCRIPTION The Hesston Model 4600 Beeline is a pull-type, centrefeed, 540 rpm, power take-off driven, automatic twine tie baler. A fl oating drum pickup complete with an auger delivers hay to the feed chamber, where it is fed into the bottom of the 356 x 457 mm (14 x 18 in) bale chamber by a series of packer and stuffer fi ngers. Hay is compacted and bales formed by a slicing plunger operating at 92 strokes per minute. FIGURE 1 shows the location of major components while detailed specifi cations are given in APPENDIX I. SCOPE OF TEST The Hesston 4600 was operated in a variety of crops (TABLE 1) for 104 hours while producing 21,285 bales. It was evaluated for rate of work, quality of work, power consumption, ease of operation, ease of adjustment, operator safety and suitability of the operator s manual.

3 TABLE 1. Operating Conditions Crop Hours Number of Bales Alfalfa Alfalfa, Bromegrass Bromegrass Greenfeed - Barley - Oats Wheat Straw Barley Straw Oat Straw Total ,285 RESULTS AND DISCUSSION RATE OF WORK Average feedrates varied from 2 t/h (2.2 ton/h) in light barley straw to 11 t/h (12.1 ton/h) in heavy alfalfa. Average feedrate depended on windrow size and uniformity, crop condition, fi eld surface, available tractor speeds and operator skill. Speeds were normally limited to about 10 km/h (6.2 mph) due to bouncing on rough ground and poorer pickup performance at higher speeds. In heavy, uniform alfalfa windrows, instantaneous feedrates up to 22 t/h (24.2 ton/h) were measured. These were peak values, representing maximum baler capacity, which could not be maintained continuously. Feeding was aggressive and smooth fl owing in all crops. Feedrate was usually limited by slipping of the power take-off shaft slip clutch or shearing of the fl ywheel shear bolt. A B QUALITY OF WORK Bale Quality: The Hesston 4600 was capable of producing fi rm, durable bales with square ends in most crops (FIGURE 2). Average hay bales weighed 21 to 41 kg (45 to 90 lb), while average straw bales weighed 21 to 24 kg (45 to 53 lb). Average bale density varied from 134 to 254 kg/m³ (8.3 to 15.8 lb/ft³) in hay and from 127 to 146 kg/m³ (7.9 to 9.1 lb/ft³) in straw. At higher feedrates the Hesston 4600 continued to produce bales of adequate quality for bale wagon handling. In long stemmed crops, bales with ragged looking ends would occasionally be produced (FIGURE 3). Bale Length Variation: As with most conventional square balers it was diffi cult to obtain consistent bale length, especially in non-uniform windrows. Because of the high plunger speed, bale length variation, for the Hesston 4600, usually was less than for balers with lower plunger speeds. When set for 1000 mm (39.4 in) length, bale lengths typically varied from 950 to 1050 mm (37.4 to 41.4 in). Bale length is adjusted by positioning the metering arm stop (FIGURE 4). The metering wheel advances the metering arm with each plunger stroke. Bale length uniformity depends on a consistent number of plunger strokes to form each bale. If the metering arm trips at the beginning of the last plunger stroke, rather than at the end of the stroke, bale length is increased by the length of compressed hay delivered during the last plunger stroke. Uniform feedrates are therefore important in reducing bale length variation. For the same length setting, higher feedrates usually produced longer bales. For example, in a uniform alfalfa fi eld, average bale length was 910 mm (35.9 in) when baling at 5 t/h (5.5 ton/h), but increased to 1010 mm (39.7 in) at 15 t/h (16.2 ton/h). The same trend was evident in wheat straw with average bale length increasing from 1025 mm (40.4 in) at 3 t/h (3.3 ton/h) feedrate to 1140 mm (44.8 in) at 15 t/h (16.2 ton/h). Leaf and Stem Loss: As with most conventional square balers, leaf loss in dry hay was lower than with round balers. Total loss from the pickup and bale chamber was less than 3% in dry alfalfa. At optimum baling conditions in alfalfa the total loss was less than 2%. Pickup losses were normally insignifi cant unless ground speed was very high or windrows were poorly formed. Proper moisture content at the time of baling is the most important factor in keeping leaf loss to a minimum. Knotter Reliability and Performance: The knotters when properly adjusted performed well with both sisal and synthetic twines. Only minor fi eld adjustments were required when changing from sisal to synthetic twine or vise-versa. C D FIGURE 2. Typical Bales: (A) Alfalfa, (B) Bromegrass, (C) Greenfeed, (D) Straw. FIGURE 3. Ragged Bale Ends in Long Stemmed Crops. POWER CONSUMPTION Power Take-off Requirements: FIGURE 5 shows typical instantaneous power take-off requirements for the Hesston Power requirements fl uctuated from 0 to 67 kw (0 to 90 hp) on each plunger stroke. Due to these wide power fl uctuations, average power requirements were less than instantaneous requirements, varying from 4 to 23 kw (5 to 31 hp) over a full range of feedrates. FIGURE 6 shows the average power take off requirements at various feedrates in alfalfa and wheat straw. Page 3

4 ineffi cient operation. The specifi c capacity of the Hesston 4600 varied from 0.7 to 1.0 t/kw h (0.6 to 0.8 ton/hp h) in alfalfa and from 0.5 to 0.7 t/kw h (0.4 to 0.6 ton/hp h) in wheat straw. This compares to an average specifi c capacity of 0.5 t/ kw h (0.4 ton/hp h) for large round balers in alfalfa. These values represent average conditions and not peak output. FIGURE 4. Bale Length Adjustment: (A) Metering Arm, (B) Metering Wheel, (C) Adjustable Stop. FIGURE 5. Instantaneous Power Take-off Requirements when Baling Alfalfa at an 11 t/h Feedrate. FIGURE 6. Average Power Take-off Requirements when Baling Alfalfa and Wheat Straw. Tractor Size: The manufacturer recommended that a 2 to 3 plow (about 25 kw) (35 hp) tractor be used. Average power takeoff requirements were usually less than 23 kw (31 hp) and power required to pull the baler on level ground was usually less than 4 kw (5 hp). A 45 kw (60 hp) tractor was, however, needed to fully utilize baler capacity in soft or hilly fi elds and to overcome the power fl uctuations illustrated in FIGURE 5. Specific Capacity: Specifi c capacity is a measure of how effi ciently a machine performs a task. A high specific capacity indicates effi cient energy use while low specifi c capacity indicates Page 4 EASE OF OPERATION Hitching: The Hesston 4600 was easily hitched to tractors equipped with a 540 rpm power take-off. The hitch jack was convenient for raising or lowering the hitch tongue and was conveniently stored, when not in use, on a tongue-cross member. The hitch clevis was not adjustable, however the baler could be levelled by repositioning the axle spindles. The power take off shaft support bearing was adjustable to obtain proper power take-off alignment. Transporting: The Hesston 4600 towed directly behind the tractor for both transport and fi eld operation. Dismounting the tractor was necessary to fold the bale chute and raise the pickup. Normally it took about two minutes to prepare the baler for transport or fi eld operation. A standard 75 x 200 mm (3 x 8 in) hydraulic cylinder could be installed under the right side of the baler to raise and lower the pickup. The baler towed well behind a tractor or suitably sized truck. Feeding: Feeding was aggressive and smooth fl owing in all crops with only infrequent plugging. Unplugging the baler could usually be done by releasing the bale chamber tension and intermittently engaging the power take-off with the tractor at half throttle. The pickup was wide enough to accommodate most windrows. Tractor wheels should be set far enough apart to straddle windrows in order to minimize trampling. Pickup visibility was excellent from most tractors. Maneuverability: With a little operator experience and skill, the Hesston 4600 was easily maneuverable for effi cient baling. Care had to be taken on sharp corners to prevent rear tractor tire interference with the hitch tongue. Visibility: Visibility to the rear was reduced due to the high baler profi le. Baler misties did not become evident as soon as with lower profi le balers. Twine Threading: Twine threading was convenient. The operator s manual gave a clear description of twine threading procedures. Access to the twine storage compartment was somewhat inconvenient due to its 1.36 m (4.5 ft) height above the ground. EASE OF ADJUSTMENT Bale Length: Bale length was conveniently adjusted with a wrench. Bale length settings from 305 to 1320 mm (12 to 52 in) were possible. Obtaining a consistent bale length was diffi cult, since bale lengths varied, depending on windrow uniformity and feedrate. Bale Density: Bale density was adjusted by hand cranks located at the rear of the bale chamber. Setting the cranks for a specifi c crop was a trial and error procedure and required the operator to dismount the tractor. The hand cranks had suffi cient adjustment range to produce bales of adequate density in most crops. Normally, twine knot strength was the only factor limiting bale density. In very dry conditions or light windrows, adding bale wedges in the bale chamber helped increase bale density. Feeding System: No packer and stuffer fi ngers (FIGURE 1) adjustment was available and none was required to produce well formed bales in all crops. Periodic tension adjustment of the packer stuffer drive-chain was required. Pickup: Pickup height was easily adjusted with a screw crank (FIGURE 7). A standard hydraulic cylinder could be installed under the right side of the baler to raise and lower the pickup for transporting. Wrenches were required to position the pickup gauge wheels. Damage to the gage wheels could occur on sharp turns if they were set too low. The pickup windguard was not adjustable. Overload Devices: The power take-off shaft slip clutch slipped at each plunger stroke at normal feedrates, when adjusted to the manufacturer s specifi cations. The slipping caused excessive heating and slip clutch wear. For effi cient baling, slip clutch torque settings up to 50 per cent higher were required. It is recommended that the manufacturer consider re evaluating the power take-off shaft

5 slip clutch torque setting given in the operator s manual. The pickup drive slip clutch required no adjustment during the test. Replacing the fl ywheel, packer-stuffer pickup drive and the knotter drive shear bolts was convenient. OPERATOR S MANUAL The operator s manual was well written and contained much useful information on operation, servicing, adjustments and safety procedures. Adjustment specifi cations given for the power takeoff shaft slip clutch, plunger safety latch and the pickup drive belt tension were inadequate for effi cient operation. DURABILITY RESULTS TABLE 2 outlines the mechanical history of the Hesston 4600 during 104 hours of fi eld operation while baling 21,285 bales. The intent of the test was functional evaluation. The following failures represent only those, which occurred during functional testing. An extended durability evaluation was not conducted. TABLE 2. Mechanical History Item Operating Hours Equivalent Bales FIGURE 7. Pickup Height Adjustment. Bale Chute: The Hesston 4600 bale chute could be mounted as either a rear drop or quarter turn bale chute (FIGURE 8). The quarter turn bale chute was easily adjusted to place the bales on edge and was reversible so bales could be dropped on either the left of right side. Drive Train -The power take-off shaft slip clutch was readjusted at beginning of test -The power take-off latch pin broke and was replaced at Pickup Assembly -The pickup drive belt began to slip excessively and was tightened at beginning of test -The pickup auger drive chain required tightening at Feeding Assembly -The packer-stuffer fi nger drive chain required tightening at -Two set screws on the packer fi nger drive sprocket and one on the stuffer fi nger drive sprocket were lost. All set screws were replaced complete with jam nuts at Plunger Assembly -The plunger crank safety stop required re-adjustment at Knotter Assembly -The wear pin in the eye of the left needle was lost and replaced at -The knotter brake was loose, allowing the needles to move into the bale chamber out of time. The brake was tightened at -The knotter drive chain required tightening at Bale Chute -The bolt on the bale chute defl ector arm was lost and replaced at 46, 74, 81, 92, 96, 97, , , , 19, 48, , ,130, 17,600, 18,300, 19,890, 20,280, 20,400, 21,180 5, , 13,250 13, , 13,250 20,400 50, 5510, 11,210, 21, , , 18,350 20,400 DISCUSSION OF MECHANICAL PROBLEMS DRIVE TRAIN Slip Clutch: Continual slipping of the power take-off shaft slip clutch (FIGURE 9) at the manufacturer s recommended torque setting, resulted in slip clutch disc wear and required frequent adjustment. It has already been recommended that the manufacturer consider re-evaluating the power take-off shaft slip clutch torque setting given in the operator s manual. FIGURE 8. Bale Chute. Servicing: The Hesston 4600 had one belt drive, three chain drives, 33 grease fi ttings and one gearbox. The operator s manual recommended frequent chain oiling, lubrication of 32 grease fi ttings every 8 hours, lubrication of one grease fi tting every 16 hours, and annual servicing of the gearbox and wheel bearings. About eight minutes were needed to service the Hesston Servicing the knotters was inconvenient due to their height above the ground. Tool Box: A tool box compartment located on the left side on the hitch tongue was convenient for carrying tools, spare shear bolts or spare parts. OPERATOR SAFETY The Hesston 4600 was safe to operate and service if normal safety precautions were observed. All moving parts were well shielded. As with most power take-off equipment, the power take-off must be disengaged and the tractor engine stopped before adjusting or servicing. FIGURE 9. Power Take-off Shaft Slip Clutch. PICKUP ASSEMBLY Pickup Drive Belt Tensioning Spring: The belt tensioning spring had to be adjusted beyond the length recommended in the operator s manual to prevent excessive belt slipping. Following this adjustment, no further problems occurred. Page 5

6 PLUNGER ASSEMBLY Plunger Safety Stop: The plunger safety stop to plunger crank arm clearance had to be adjusted beyond the clearance recommended in the operator s manual. This correction was later confi rmed by a company service bulletin. Occasional readjustment of the plunger safety stop was required due to wear between the safety stop actuating lever and the needle carriage and due to fl aring on the end of the plunger safety stop from striking the plunger crank arm. APPENDIX I SPECIFICATIONS MAKE: Hesston MODEL: 4600 SERIAL NUMBER: B OVERALL DIMENSIONS: (Field Position) -- width 2520 mm -- length 6060 mm -- height 1720 mm -- ground clearance 105 mm WEIGHTS: -- left wheel 780 kg -- right wheel 660 kg -- pickup gauge wheels 0 kg -- hitch 360 kg Total 1800 kg TIRES: -- left 9.5L-14, 6-ply rating, tubeless -- right 9.5L-14, 6-ply rating, tubeless -- pickup gage 3.00 x 12, semi-pneumatic PICKUP: -- type cam actuated drum pickup -- height adjustment hand crank adjustment -- width 1960 mm -- number of tooth bars 4 -- number of teeth tooth spacing 66 mm -- speed 113 rpm FEEDING MECHANISM: -- type packer and stuffer fi ngers -- auger diameter 457 mm -- auger speed 113 rpm -- packer fi nger speed 101 rpm -- stuffer fi nger speed 92 rpm PLUNGER: -- strokes per minute length of stroke 584 mm TWINE CAPACITY: DRIVES: -- number of belt drives 1 -- number of chain drives 3 -- number of gear drives 1 -- number of universal joints 3 6 balls SAFETY FEATURES: -- power take-off slip clutch -- fl ywheel shear bolt -- pickup drive slip clutch -- packer, stuffer, pickup drive shear bolt -- knotter drive shear bolt -- plunger safety stop SERVICING: -- grease fi ttings 32, every 8 hours 1, every 16 hours -- chains 3, oil frequently -- gearbox 1, service annually -- wheel bearings 2, service annually OPTIONAL EQUIPMENT: -- bale chute kit* (combination rear drop and quarter turn chute) -- bale chute extension -- hydraulic density control kit -- wagon hitch -- decal kit -- light kit -- bale thrower kit (*supplied on test machine) APPENDIX II MACHINE RATINGS The following rating scale is used in PAMI Evaluation Reports: (a) excellent (d) fair (b) very good (e) poor (c) good (f) unsatisfactory APPENDIX III CONVERSION TABLE 1 hectare (ha) = 2.5 acres (ac) 1 kilometre/hour (km/h) = 0.6 miles/hour (mph) 1 tonne (t) = 2200 pounds mass (lb) 1 tonne/hour (t/h) = 1.10 ton/hour (ton/h) 1 tonne/hectare (t/ha) = 0.45 ton/acre (ton/ac) 1 millimetre (mm) = 0.04 inches (in) 1 metre (m) = 39.4 inches (in) 1 kilowatt (kw) = 1.3 horsepower (hp) 1 kilogram (kg) = 2.2 pounds mass (lb) 1 kilogram/cubic metre (kg/m³) = 0.06 pounds mass/cubic foot (lb/ft³) 1 tonne/kilowatt hour (t/kw h) = 0.8 ton/horsepower hour (ton/hp h) BALE CHAMBER: -- width 457 mm -- height 356 mm -- range of bale lengths 305 mm to 1320 mm -- bale density control compression rails (primary) hay wedges (secondary) 3000 College Drive South Lethbridge, Alberta, Canada T1K 1L6 Telephone: (403) FAX: (403) afmrc/index.html Prairie Agricultural Machinery Institute Head Offi ce: P.O. Box 1900, Humboldt, Saskatchewan, Canada S0K 2A0 Telephone: (306) Test Stations: P.O. Box 1060 P.O. Box 1150 Portage la Prairie, Manitoba, Canada R1N 3C5 Humboldt, Saskatchewan, Canada S0K 2A0 Telephone: (204) Telephone: (306) Fax: (204) Fax: (306) This report is published under the authority of the minister of Agriculture for the Provinces of Alberta, Saskatchewan and Manitoba and may not be reproduced in whole or in part without the prior approval of the Alberta Farm Machinery Research Centre or The Prairie Agricultural Machinery Institute.